What is Hybrid injection processes?

Hybrid injection molding processes represent an evolution in injection molding technology by integrating traditional methods with complementary techniques to enhance performance, functionality, and sustainability of plastic parts. These processes combine different technologies in a single operation or continuous production cycle, allowing the manufacture of more complex, lightweight components with improved properties—without requiring additional steps.

Among the main types of hybrid injection molding processes are insert molding, injection-blow molding, injection-compression molding, co-injection, gas or water-assisted injection, and overmolding. Each of these methods offers specific advantages depending on the type of part, functional requirements, and application sector.

For example, in insert molding, metal or other material elements are placed inside the mold before injection, enabling the creation of a single part with combined properties such as electrical conductivity, mechanical strength, or magnetic features. This hybrid process is common in the electronics, automotive, and medical industries.

Hybrid injection molding processes also optimize material usage. With co-injection, for instance, two different materials can be used in a single part—such as a recycled core with a virgin outer layer—reducing cost and environmental impact without compromising surface quality. This technique is especially useful in consumer goods or technical parts requiring structural integrity and aesthetics.

Another key example is overmolding, where a pre-molded part is placed in a second mold to inject another material over it, creating a permanent bond. This technique is essential in the production of ergonomic handles, buttons, seals, or multi-component parts. It is highly valued in industries like hand tools, medical devices, and consumer products.

In addition, hybrid injection molding processes offer significant productivity benefits. By combining operations in one cycle, they reduce assembly time, handling, and the risk of assembly errors. Product quality is also improved thanks to stronger, more uniform bonds without adhesives or fasteners.

At Plásticos Lezo, we are constantly evolving to incorporate hybrid injection molding processes that allow us to deliver more efficient, customized, and sustainable solutions. We assess each project holistically to determine whether combining technologies adds value—be it in cost, functionality, or weight reduction. We use advanced simulation tools and collaborate closely on the design of parts and molds optimized for these processes.

Our clients see these systems as an opportunity to differentiate their products, integrate more functions into fewer components, and shorten development timelines. Moreover, by reducing the amount of materials and operations involved, hybrid injection molding processes contribute to the improved sustainability of the final product—an increasingly valued feature across all sectors.

In summary, hybrid injection molding processes are a strategic alternative for developing more complex, lightweight, and functional plastic parts. When properly implemented, they help enhance industrial competitiveness, optimize material and energy use, and deliver innovative solutions that meet today’s market demands.